Face protector lens assembly and method of use

ABSTRACT

A retainer lens of shape and dimensions configured to be releasably secured in the front opening of a face plate or helmet has a window opening configured for positioning in front of the eyes of a wearer of the face plate or helmet. An outer protective cover is configured to be secured over the window opening by means of scrap-book like frame corners located on the front surface of the retainer lens and spaced outwardly from respective corners of the window opening. The corners of the outer protective cover are releasably engaged with respective frame corners, so that the cover can be removed from the outside of the face plate as needed for replacement with a new outer protective cover, simply by removing the corners of the current outer protective cover from the respective frame corners, and then engaging a new outer protective cover into the frame corners.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a Continuation In Part of U.S. patentapplication Ser. No. 13/893,192 filed on May 13, 2013, which is aContinuation of U.S. patent application Ser. No. 13/081,699 filed Apr.7, 2011, now U.S. Pat. No. 8,438,663, which is a Continuation In Part ofpatent application Ser. No. 12/950,846 filed on Nov. 19, 2010, now U.S.Pat. No. 8,438,662, which claims the benefit of U.S. provisional pat.App. Ser. No. 61/263,765, filed Nov. 23, 2009, and the contents of eachof the aforementioned applications are incorporated herein by referencein their entirety.

BACKGROUND

1. Field of the Invention

The present invention relates, in general, to lenses of face protectors,and, in particular, to lenses of welding masks or helmets.

2. Related Art

Welding helmets or masks are headgear used when performing certain typesof welding to protect the eyes, face and neck from flash burn,ultraviolet light, sparks and heat. Welding helmets are necessary toprevent arc eye, a painful condition where the cornea is inflamed.Welding helmets can also prevent retina burns, which can lead to a lossof vision. Both conditions are caused by unprotected exposure to thehighly-concentrated UV rays emitted by the welding arc (which can alsodamage uncovered skin, similar to a sunburn).

All welding helmets include a small window, called a lens, through whichthe welder looks at the weld. In older helmets, the window can be madeof darkly tinted glass, or perhaps a pair of polarized lenses. In moremodern helmet designs, transparent material that darkens automaticallywhen exposed to the flare of a welding arc are more common. Either type,however, is susceptible to damages such as cracks that can compromisethe protection from ultraviolet rays. In addition to the lens shade, thehelmet has a shroud around the face to protect it from hot metal sparksgenerated by the arc.

The hot metal sparks generated by the arc can ignite flammable objectsin the welding area. Because the welding helmets include a small windowdirectly in front of the welder's eyes and have obstructed peripheralvision or even no peripheral vision, a welder may not recognize that thehot metal sparks generated a fire in the area (e.g., to the sides) ofthe welder. The obstructed peripheral vision also prevents the welderfrom clearly seeing the future direction of their welding line, and theyalso may not see potential dangers such as people walking up to themfrom the side or objects moving or falling into their path.

SUMMARY OF THE INVENTION

To solve these problems and others, the present invention involves alens-in-a-lens assembly that protects a users eyes (e.g., duringwelding), while also allowing peripheral vision.

In one embodiment, a lens assembly for a face plate of a face protectorhas a first, retainer lens of shape and dimensions configured to besecured in a front opening of the face plate and having a curvaturesubstantially matching the curvature of the face plate, and a secondlens of smaller dimensions secured behind the first lens to provide alens-in-a-lens configuration, with the second lens configured to extendacross the eyes of a wearer of the face protector and the first lensextending around the sides of the wearer's face to provide peripheralvision. The lenses may be of tinted glass or may be automatic darkeningfilter (ADF) lenses which darken automatically when exposed to increasedlight such as the flare of a welding arc, and one or both lenses may beselected from sets of interchangeable lenses having different shades.

In one embodiment, the ADF retainer lens has a window opening alignedwith the ADF lens, and four “scrap book frame” type corners formedintegrally in its front face around the window opening for engagementwith corners of an outer protective lens or cover. This makes it easierfor users to replace the outer protective lens or cover without needingto disassemble the cover from the inside of the welding helmet or faceprotector in which the lens assembly is mounted. Since the outerprotective lens or cover is exposed to a welding environment in whichscratching and damage is common, the cover sometimes needs to bereplaced multiple times in one day of work. By making the outerprotective lens replaceable quickly and easily from the front of thehelmet or face protector simply by releasing it from the externallyaccessible scrap book frame corners, without requiring any disassembly,workers can be much more productive.

In one embodiment, the second lens may be releasably secured behind thefirst lens by a retainer assembly having a rear retainer frame and agasket between the retainer frame and second lens, and the rear retainerframe is secured to the first lens by one ore more releasable fasteners.This allows the second lens to be replaced by second lenses of differentproperties, while the flexible gasket allows second lenses of differentdepths to be secured in the assembly.

Other features and advantages of the present invention will become morereadily apparent to those of ordinary skill in the art after reviewingthe following detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The details of the present invention, both as to its structure andoperation, may be gleaned in part by study of the accompanying drawings,in which like reference numerals refer to like parts and in which:

FIG. 1 is a front exploded and partially cut-away perspective view of anembodiment of a face protector with an embodiment of a lens assemblyshown therein.

FIG. 2 is a rear exploded perspective view of the face protector and thelens assembly shown in FIG. 1.

FIG. 3 is a front perspective view of the face protector and the lensassembly shown in FIGS. 1 and 2, with a strap assembly attached to holdthe face protector in position on a user's head.

FIG. 4 is a rear perspective view of the face protector and the lensassembly shown in FIGS. 1 to 3.

FIG. 5 is a bottom plan view of the face protector and the lens assemblyshown in FIGS. 1 to 4.

FIG. 6 is a top plan view of the face protector and the lens assemblyshown in FIGS. 1 to 5.

FIG. 7 is a rear elevational view of the face protector and the lensassembly shown in FIGS. 1 to 6.

FIG. 8 is a right side elevational view of the face protector and thelens assembly shown in FIGS. 1 to 7, the left side elevational viewbeing a mirror image thereof.

FIG. 9 is a front elevational view of the face protector and the lensassembly shown in FIGS. 1 to 8, the left side elevational view being amirror image thereof.

FIG. 10 is a front exploded and partially cut-away perspective view ofthe face protector of FIGS. 1 to 9 but with a modified lens assemblyincluding a spacer gasket;

FIG. 11 is a rear exploded perspective view of the face protector andlens assembly of FIG. 10;

FIG. 12 is a rear perspective view of another embodiment of a faceprotector incorporating another embodiment of a lens assembly;

FIG. 13 is a bottom plan view of the face protector of FIG. 12;

FIG. 14 is a front elevation view of the face protector of FIGS. 12 and13;

FIG. 15 is a top plan view of the face protector of FIGS. 12 to 14;

FIG. 16 is a rear elevation view of the face protector of FIGS. 12 to15;

FIG. 17 is a right side elevation view of the face protector of FIGS. 12to 16;

FIG. 18 is a rear exploded view of the face protector of FIGS. 1 to 9with a modified lens-in-a-lens assembly (lens assembly) including anoptional cheater or magnifying lens;

FIG. 19 is a rear perspective view of the modified back plate of thelens assembly of FIG. 18;

FIG. 20 is a front elevation view of the light block/spacer of theassembly of FIG. 18;

FIG. 21 is a rear perspective view, partially cut away, of the assembledlens assembly of FIG. 18;

FIG. 22 is rear perspective view of the entire lens assembly whenassembled, excluding other parts of the face protector;

FIG. 23 is a perspective view of a modified embodiment of an ADF holderlens including a front mountable outer protective lens or cover for usewith the helmet or face protector of any of the previous embodiments;

FIG. 24 is a front exploded and partially cut-away perspective view of aface protector including the modified ADF holder lens of FIG. 23; and

FIG. 25 is a front perspective view of the assembled face protector orhelmet of FIG. 24.

DETAILED DESCRIPTION

Certain embodiments as disclosed herein provide for a face protectorhaving a face plate with a front opening which extends across the eyeregion of a wearer and rearwardly around the sides of the face towardsthe ears, and a lens-in-a-lens assembly secured in the front opening.

After reading this description it will become apparent to one skilled inthe art how to implement the invention in various alternativeembodiments and alternative applications. However, although variousembodiments of the present invention will be described herein, it isunderstood that these embodiments are presented by way of example only,and not limitation. As such, this detailed description of variousalternative embodiments should not be construed to limit the scope orbreadth of the present invention.

With reference to FIGS. 1-9, a first embodiment of a lens-in-a-lensassembly (“lens assembly”) 100 of a face protector 105 will bedescribed. In an exemplary embodiment, the face protector 105 is used ina welding application; however, in an alternative embodiments, the faceprotector 105 and/or face plate 110 is used in other applications suchas, but not limited to, safety applications, commercial applications,do-it-yourself (DIY) applications, grinding, splash guard, sandblasting, food preparation, fork lift operations, tile cutting, woodcutting, wood chopping, face protection from flying particles, forcedhigh pressure washing applications, during boat travel in sport leisureand commercial fishing, snowboarding, skiing, snowmobiling, hiking,hunting, paint ball, law enforcement, fire fighting, motorcycling, dunebuggy or rails, ATV, air soft, spectator sports (e.g., NASCAR carracing, NFL/college football, NHL/college hockey), commercial activitiessuch as airline industry, landscaping, and governmental activities suchas military, lake patrols, etc.

With reference to FIG. 3, before describing the lens assembly 100, theface protector 105 will be generally described. The face protector 105protects the front of a user's head (i.e., forehead, face, eyes, cheeks,jaw, chin, mouth, nose, ears) from flash burn, ultraviolet light,sparks, heat, and/or other elements associated with theactivity/application.

The face protector 105 includes a face plate 110 preferably made of aninjection molded thin, plastic material. The face plate 110 has aconfiguration generally similar to the configuration of a human face andincludes a forehead portion 120, a cheek portion 130, a jaw portion 140,a mouth portion 142, a nose portion 144, ear portions 146, a chinportion 148, and the replaceable/interchangeable lens assembly 100 thatcover and protect the forehead, cheeks, jaw, mouth, nose, ears, chin,and eyes, respectively, of a user.

The forehead portion 120 is just wider than the width of the head of theuser, is curved rearwardly, and extends from the brow area to just abovethe forehead area of the user. Substantially all of the skull is notcovered by the forehead portion 120 or the rest of the face protector110. Although not shown, in alternative embodiments, the foreheadportion 120 may include one or more ventilation sections for ventilatingthe face protector 110. On a front side 160 of the forehead portion 120,the forehead portion 120 may include an insert and/or indicia 182displaying a trademark, logo, or other insignia pertinent to theapplication of the face protector 110. The mold used to make the faceprotector 110 may include different mold inserts for the differentindicia so that the same mold, but different mold inserts, may be usedto manufacture the face protectors 110 for different applications.

The cheek portion 130 is curved rearwardly from the nose portion 144 andthe mouth portion 142 of the face plate 110, and protects the cheeks ofa user.

The jaw portion 140 is curved rearwardly from the mouth portion 142 andthe cheek portion 130 of the face plate 110, and protects the jaw areaof a user. The jaw portion 140 includes the chin portion 148, which hasa cupped configuration for receiving the chin of a user. The jaw portion140 decreasingly tapers in width from the top of the jaw portion 140,just below the lens assembly 100, to the bottom of the chin portion 148.

The mouth portion 142 is disposed between the nose portion 144 and thejaw portion 140, and protects the mouth of a user. Although not shown,in an alternative embodiment, the mouth portion 142 may includeventilation holes in the grooves shown or in other areas of the mouthportion 142 and/or nose portion 144. The mold used to make the faceprotector 110 may include different inserts for the different mouthand/or nose designs so that the same mold, but different inserts, may beused to manufacture the face protectors for different applications (e.g.face protectors with and without mouth/nose ventilation holes).

The front side of the nose portion 144 may bow outward and the rear side162 of the nose portion 144 may be concave to accommodate the nose ofthe user. Although not shown, as discussed above, the nose portion 144may include one or more ventilation holes in alternative embodiments.

The ear portions 146 extend rearwardly from the opposite ends of thelens assembly 100, and decreasingly taper in dimension progressingrearwardly, and protect the entire ears of the user. As illustrated inFIG. 2, substantially rectangular-shaped holes 170 are disposed in upperportions of the ear portions 146 for attaching a suitable strapassembly. FIG. 3 illustrates a strap assembly 410 with connectors 412connected through the holes 170 in the back side of ear portions 146 ofthe face plate. Strap assembly 410 is used to retain face protector 100in position on the user's head. The straps 414 of assembly 410 may beelastic or adjustable to accommodate a range of different size heads.

The face protector 110 may come in a one-size-fits-all configuration ormay come in different sizes for different-sized heads (e.g., XL, L, M,S, child size).

An inner/back side of the face plate 110 may include cushion member(s)to provide added comfort to the user when wearing the face protector105. The cushion member(s) may be affixed or connected to an inner/backside of the face plate 110 using an adhesive and/or fasteners. Thecushion member(s) may be made of a waterproof, breathable material. Thecushion member(s) may include holes therein to increase thebreathability and comfort of the cushion member(s) when against the skinof the user. The cushion member(s), like the face plate 110, may come indifferent sizes to allow the user to custom fit the face protector 105for the user's specific facial dimensions.

Because of the face-forming, low profile of the face plate 110,especially in the jaw portion 140, the face plate 110 allows the user tomove one's head from side to side more easily because the lower jaw areaof a normal welding helmet or mask hits the users shoulders and causesthe helmet/mask to push up and/or off the user's face/head. Also,because of the rounded profile of the face plate 110, air flows betterthan other welding helmets because there is no 90-degree angle that theair has to move past. For example, the forehead portion 120 of the faceplate 110 has a rounded profile compared to the 90-degree angles ofother welding helmets. Also, because of the rounded spherical lensassembly 100, which will be described in more detail below, splatter,flying objects, and the like ricochet off the lens assembly 100 and faceplate 110 with less impact and stress on the face plate 110, and thelens assembly 100 does not scratch so easily.

With reference generally to FIGS. 1-9, the lens assembly 100 will now bedescribed in more detail. The lens assembly 100 protects the user's eyesfrom flash burn (e.g., causing arc eyes, retina burns), ultravioletlight, sparks, heat, and/or other elements associated with theactivity/application. The lens assembly 100 also maximizes the user'sgeneral vision and peripheral vision, which helps the user to spot firesin the welding area (e.g., to the sides of the user) caused by hot metalsparks generated by the arc that ignite flammable objects.

The lens assembly 100 is replaceable/interchangeable with other lenses(e.g., for different welding applications, for different applications)and fits within an eye opening 190 (FIG. 1) of the face plate 110. Thelens assembly 100 includes an Automatic Darkening Filter (“ADF”)retainer lens 200, a front cover 210, an ADF lens 220, a polycarbonatelens protector 230, a back cover or rear retainer frame 240, flat headscrews 250, and threaded inserts 260.

The ADF retainer lens 200 is partially spherical, toroidal, and/orcylindrical, providing the user with 180 degree viewing and unobstructedperipheral vision. Opposite peripheral/temple portions 270 of the ADFretainer lens 200 include crescent-shaped holes 280 that overlapcrescent-shaped holes 290 in recessed eye opening section 300. Fastenersmay extend through the holes 280, 290 for connecting the ADF retainerlens 200 to the recessed eye opening section 300 of the face plate 110.The ADF retainer lens 200 includes a central section with a rectangularopening 310 having front upper and lower recessed sections 320, sidecut-outs 330, and rearwardly extending receiving section 335. Therearwardly extending receiving section 335 includes rearwardly extendingupper horizontal member, lower horizontal member, and side verticalmembers that together form an air/space pocket between the ADF lens 220and the front cover 210 when the lens assembly 100 is assembled. In oneembodiment, the ADF retainer lens 200 is a #10 shaded lens and is madeof polycarbonate. In alternative embodiments, the ADF retainer lens 200is a shaded lens in the range of #2-#12 shaded lens.

The front cover 210 protects the ADF lens 220 from impact. The frontcover 210 is transparent, un-shaded,rectangular/spherical/torical/cylindrical, made of polycarbonate and hasa slight curved configuration/shape. Although front cover 210 is aseparate component secured in an opening in the retainer lens in theillustrated embodiment, it may alternatively comprise a transparent orsubstantially transparent cover portion formed integrally with theretainer lens. The front cover 210, when disposed in the ADF retainerlens 200, is flush with the outer surface of lens 200. Rearwardextending latch projections 340 extend from opposite sides 350 of thefront cover 210 and extend through the side cut-outs 330 of the ADFretainer lens 200 (see FIGS. 1 and 2).

As indicated above, the lens assembly 100 has a lens-in-a-lens designwith the ADF retainer lens 200 forming an outer holder lens and the ADFlens 220 forming an inner lens carried within/by the ADF retainer lens200. Threaded inserts 260 are injected/added into a rear/back side ofthe ADF retainer lens 200.

The ADF lens 220 is substantially rectangular and has a rectangularframe portion and a rectangular lens portion held in the rectangularframe portion. In the embodiment shown, the ADF lens 220 is a 2 in.×4.25in. ADF lens and is a shade #3 normally and darkens to shade #10automatically when exposed to the flare of a welding arc. The ADF lens220 is interchangeable with other 108 mm×50.8 mm×5 mm ADF filters andshades. In further embodiments, the outer ADF retainer lens 200 is ashade which matches the shade of the ADF lens 220, but these lenses maybe of different shades in other embodiments. In an alternativeembodiment, the ADF lens 220 is a 4 in.×4 in. or 4 in.×5 in. ADF lens,as described below in connection with the embodiment of FIGS. 10 to 15.In further embodiments, the ADF lens 220 and/or the outer ADF retainerlens 200 may be made of different shades and/or different types of ADFlenses.

A rectangular polycarbonate lens protector 230 is disposed behind theADF lens 220.

The rectangular back cover 240 includes a central rectangular opening360 and forwardly extending upper/lower flange members 370. A front ofthe back cover 240 includes a rectangular recessed section 380 with sidecut-outs 390. The recessed section 380 in the front of the back cover240 receives/retains the polycarbonate lens protector 230 and the ADFlens 220. The rearwardly extending latch projections 340 of the frontcover 210 latch into the side cut-outs 390 of the back cover 240. Theflat head screws 250 are inserted through holes in the corners of theback cover 240 and threadably engage the threaded inserts 260 in therear side of the ADF retainer lens 200 to connect/assemble therectangular back cover 240, the polycarbonate lens protector 230, andthe ADF lens 220, the ADF retainer lens 200, and the front cover 210 ofthe lens assembly 100 together.

Thus, the lens assembly 100 protects the user's eyes from flash burn,ultraviolet light, sparks, heat, and/or other elements associated withthe activity/application, and maximizes the user's peripheral/overallvision. Increased peripheral vision helps the user to spot fires orother objects in the welding area (e.g., to the sides of the user)caused by hot metal sparks generated by the arc that ignite flammableobjects.

FIGS. 10 and 11 illustrate a modification of the lens assembly 100 ofFIGS. 1 to 9 in which a rear rectangular gasket or gasket plate 241 isadded between the back cover or retainer 240 and the lens protector 230.Gasket 241 is of approximately the same dimensions as rear retainer orcover 240, and has a rectangular opening 242 of similar size alignedwith opening 360. As illustrated in FIGS. 10 and 11, the opposite sides243 of gasket 241 are inset relative to the sides 380 of rear cover 240to allow clearance for fastener screws 250 when the components of thelens assembly are fastened together. The rear gasket 241 allowsdifferent ADF lenses 220 with different depths to be used in the lensassembly, for example generic ADF lenses. The rear gasket 241, backcover 230, and ADF lens 220 are held between back cover 240 and lensprotector 230 by the screws 250 which secure back cover 240 to thethreaded inserts in ADF retainer lens 200. The rear gasket 241 allowslens 220 to be exchanged for other ADF lenses 220 having different lensproperties and/or different depths, as noted above. All other parts ofthe lens assembly are identical to the lens assembly 100 of FIGS. 1 to9, and like reference numbers are used for like parts as appropriate.

FIGS. 12 to 17 illustrate a second embodiment of a face protector 400comprising a face plate 401 having a front opening 402. A lens-in-a-lensassembly 100A which is similar to that of the previous embodiment but ofdifferent dimensions is mounted in front opening 402 in the same manneras described in the previous embodiment for lens assembly 100. Parts ofassembly 100 a which are equivalent to corresponding parts in theprevious embodiment but of different dimensions or shape are providedwith the same reference numbers as in the previous embodiment, followedby the letter A, and reference is made to the above description of theseparts in the first embodiment for details of their materials andfunctions. The lens-in-a-lens assembly 100 a and the front opening 402for receiving the assembly are both larger in this embodiment than theprevious embodiment, offering an increased viewing area to the wearer.

The face plate 401 is similar in shape and made of the same material asface plate 110 of the previous embodiment, and like reference numbersare used for like parts as appropriate. Reference is made to thedescription of these parts in connection with the previous embodiment,and the parts are not described in detail in connection with thisembodiment, apart from any variations from the previous embodiment. Astrap assembly 410 with connectors 412 which connect to the holes 170 inthe back side of ear portions 146 of the face plate is illustrated inFIGS. 12 to 17, similar or identical to the strap assembly 410 securedto face protector 100 of the first embodiment, as illustrated in FIG. 3above, and like reference numbers are used for like parts asappropriate.

As can be seen by comparing FIGS. 9 and 14, the recessed front or eyeopening 402 in the face plate 401 of this embodiment is larger than therecessed eye opening 300 of the first embodiment, and the ADF retainerlens 200 a of the lens assembly is of shape and dimensions substantiallymatching those of opening 402 so that it is a close fit in the openingwhen opposite peripheral/temple portions 270 a are secured to theopposite ear portions or side portions of the face plate. As in theprevious embodiment, retainer lens 200 a has crescent shaped holes 280 athat overlap corresponding holes in the recessed eye opening section,and fasteners 281 extend through the overlapping holes to secure theretainer lens in the recessed opening. The retainer lens 200 a is ofincreased height relative to the retainer lens 200 in the previousembodiment, so that it can accommodate a larger ADF lens 220 a. As canbe seen by comparing the rear end views of the face protectors 105 and400 in FIGS. 7 and 16, respectively, the ADF lens 220 a is of largerheight than lens 220 but of substantially the same width, and may be ofsubstantially square shape. The larger size of lenses 200 a and 220 aprovides increased visibility to the user. The other parts of the lensassembly 100 a which protect lens 220 a and releasably secure the lensto retainer lens 200 a are identical to those of the previousembodiment, apart from the increased dimensions of front cover 210 a,lens protector 230 a, and the frame or back cover 240 a which holds lens200 a, as well as the front opening 310 a in retainer lens 200, toaccommodate the increased size of lens 220 a. Apart from the change indimensions, these parts are identical to the corresponding parts in thefirst embodiment and are therefore not described in any more detail.

The dimensions of the ADF lens 220 a may be approximately 4.0 in.×4.0in. or 4 in.×5 in., with the height dimensions of retainer lens 200 a,the front opening 310 a in the retainer lens, and the recessed opening402 in the face plate in which lens 200 a is mounted similarly scaled upto accommodate the increased size of lens 220 a. As in the previousembodiment, lenses 200 a and 220 a may be of any selected initial lensshade and darkened lens shades, and lens 200 a and 220 a may be replacedor interchanged with other lenses of equivalent shapes and dimensionsbut different lens properties, as desired. As in the previousembodiment, lens assembly 100 a may be modified by addition of a reargasket similar to rear gasket 241 of FIGS. 10 and 11 but of largerdimensions to match the dimensions of ADF lens 220 a. As in theembodiment of FIGS. 1 to 11, the addition of a rear gasket between rearcover 240 a and lens protector 230 a allows the user to select ADFlenses of different depths, including generic ADF lenses.

As in the previous embodiment, the lens-in-lens assembly 100 a protectsa wearer's eyes while allowing peripheral vision, and one or both lensesare replaceable or interchangeable as described above in connection withthe first embodiment.

Another embodiment of a lens-in-a-lens assembly (“lens assembly”) 500 ofa face protector 502 is illustrated in FIGS. 18 to 22. Assembly 500 isof similar dimensions to the lens assembly 100 of FIGS. 1 to 9, but someof the parts are modified, as described in more detail below. Apart fromthe modifications to lens assembly 500, the face protector 502 isidentical to the face protector of FIGS. 1 to 9, and like referencenumbers are used for like parts as appropriate. As in the firstembodiment, lens assembly 500 is configured for mounting in an eyeopening 190 of face plate 110 of the face protector, and the remainingparts of the face protector including the face plate are identical tothose of the first embodiment and are therefore not described in detailin connection with this embodiment. As described above, the faceprotector protects the front of a user's head (i.e., forehead, face,eyes, cheeks, jaw, chin, mouth, nose, ears) from flash burn, ultravioletlight, sparks, heat, and/or other elements associated with theactivity/application.

As in the previous embodiments, the lens assembly 500 isreplaceable/interchangeable with other lenses (e.g., for differentwelding applications as well as for other applications where faceprotection is needed). The lens assembly 500 includes an AutomaticDarkening Filter (“ADF”) retainer lens 200, a front cover 210, an ADFlens 220, a polycarbonate lens protector 230, a light block/spacer 505,a back cover or rear retainer frame 508, an optional cheater lens ormagnifying glass 510, flat head screws 250, and threaded inserts 260.

In this embodiment, the back cover or retainer frame 508 is modified toaccept cheater lens 510 and a light block/spacer 505 is added. Spacer505 may be of resilient material to allow ADF lenses 220 of differentdepths to be secured in the assembly. The cheater lens or cheater glass510 has a clear lens or magnifier similar to those used in off-the-shelfreading glasses, and a peripheral rectangular frame 515, and can bereleasably attached to the back or outer face of back cover 508 whendesired by the user of the face protector for additional magnificationif needed while performing a task such as welding. As illustrated inFIG. 19, back cover 508 in this embodiment has a peripheral rectangularframe 509 with a recessed seat 512 against which the outer frame 515 ofcheater lens 510 can be seated. Seat 512 is surrounded by rearwardlyprojecting rim 514 which has cut-outs around its perimeter. A fastenermechanism is located on the rear side of the frame for releasablyattaching a selected cheater lens to the back of the frame. In theillustrated embodiment, the fastener mechanism comprises a spring clipor fastener 516 extending rearward from one side of the frame 509, and apair of retainer tabs or hooks 518 located on the opposite side of frame509. If a user wishes to use a cheater lens, they simply engage one sideof the lens frame 515 under the two tabs 518, then push the other sidepast spring clip 516, which is depressed and then springs back over theopposite side of the lens frame to hold the cheater lens in position, asillustrated in FIGS. 21 and 22. The spring clip can be pulled up andreleased by the user in order to remove the cheater lens when it is nolonger needed. Different cheater or magnifying lenses with differentmagnifications may be provided for selective attachment to the backcover as needed.

Other parts of the rectangular back cover 508 are similar to those ofthe first embodiment. Cover 508 includes a central rectangular opening360 and upper/lower flange members 370 which extend forward from upperand lower portions of the frame 509, forming a recessed section in thefront of the frame which receives/retains spacer 505, the polycarbonatelens protector 230 and the ADF lens 220, as best illustrated in FIG. 21.The light block/spacer 505 is illustrated in more detail in FIG. 20, andmay be made of resilient material with light blocking properties. Spacer505 has a rectangular peripheral frame 520 with a central opening 522.Frame 520 has light blocking projections 524, 525 projecting outwardlyat its opposite sides.

The rearwardly extending latch projections 340 of the front cover 210latch into the side cut-outs 390 of the back cover 508 when the partsare assembled (see FIG. 22), as in the first embodiment. The flat headscrews 250 are inserted through holes 520 adjacent the corners of theframe 509 and threadably engage the threaded inserts 260 (FIG. 18) inthe rear side of the ADF retainer lens 200 to connect/assemble therectangular back cover 508, the spacer 505, the polycarbonate lensprotector 230, the ADF lens 220, the ADF retainer lens 200, and thefront cover 210 of the lens assembly 500 together.

Other parts of the assembly 500 have the same or substantially the samefunction and structure as described above in connection with the firstembodiment. The ADF retainer lens 200 is partially spherical, toroidal,and/or cylindrical, providing the user with 180 degree viewing andunobstructed peripheral vision. Opposite peripheral/temple portions 270of the ADF retainer lens 200 include crescent-shaped holes 280 thatoverlap crescent-shaped holes 290 in recessed eye opening section 300.Fasteners may extend through the holes 280, 290 for connecting the ADFretainer lens 200 to the recessed eye opening section 300 of the faceplate 110. The ADF retainer lens 200 includes a central section with arectangular opening 310 having front upper and lower recessed sections320, side cut-outs 330, and rearwardly extending receiving section 335.The rearwardly extending receiving section 335 includes rearwardlyextending upper horizontal member, lower horizontal member, and sidevertical members that together form an air/space pocket between the ADFlens 220 and the front cover 210 when the lens assembly 500 isassembled, as illustrated in FIG. 21. In one embodiment, the ADFretainer lens 200 is a #10 shaded lens and is made of polycarbonate. Inalternative embodiments, the ADF retainer lens 200 is a shaded lens inthe range of #2-#12 shaded lens.

As in the first embodiment, the front cover 210 protects the ADF lens220 from impact. The front cover 210 is transparent, un-shaded,rectangular/spherical/torical/cylindrical, made of polycarbonate and hasa slight curved configuration/shape. Although front cover 210 is aseparate component secured in an opening in the retainer lens in theillustrated embodiment, it may alternatively comprise a transparent orsubstantially transparent cover portion formed integrally with theretainer lens. The front cover 210, when disposed in the ADF retainerlens 200, is flush with the outer surface of lens 200. Rearwardextending latch projections 340 extend from opposite sides 350 of thefront cover 210 and extend through the side cut-outs 330 of the ADFretainer lens 200, as described above.

As indicated above, the lens assembly 500 has a lens-in-a-lens designwith the ADF retainer lens 200 forming an outer holder lens and the ADFlens 220 forming an inner lens carried within/by the ADF retainer lens200. Threaded inserts are injected/added into a rear/back side of theADF retainer lens 200, as in the first embodiment (see FIG. 2).

The ADF lens 220 is substantially rectangular and has a rectangularframe portion and a rectangular lens portion held in the rectangularframe portion. In the embodiment shown, the ADF lens 220 is a 2 in.×4.25in. ADF lens and is a shade #3 normally and darkens to shade #10automatically when exposed to the flare of a welding arc. The ADF lens220 is interchangeable with other 108 mm×50.8 mm×5 mm ADF filters andshades. In further embodiments, the outer ADF retainer lens 200 is ashade which matches the shade of the ADF lens 220, but these lenses maybe of different shades in other embodiments. In an alternativeembodiment, the ADF lens 220 in lens assembly 502 may be a 4 in.×4 in.or 4 in.×5 in. ADF lens, as described above in connection with theembodiment of FIGS. 10 to 15. In this alternative, the shape anddimensions of the other parts of the lens assembly, including spacer505, back cover 508 and cheater lens 510, are modified appropriately forfitting together in the same way as illustrated for the rectangular lensof FIGS. 18 to 22. In further embodiments, the ADF lens 220 and/or theouter ADF retainer lens 200 may be made of different shades and/ordifferent types of ADF lenses.

FIGS. 23 to 25 illustrate a modified embodiment of a face protector orhelmet 110 having a modified lens-in-lens assembly 600 in its frontopening. In this embodiment, the ADF holder or retainer lens 200 of theprevious embodiments is replaced by ADF holder or retainer lens 605 towhich a flat, flexible outer protective cover or lens 610 is releasablysecured when the parts are assembled as illustrated in FIGS. 23 and 25.The parts are shown separate from one another in the exploded view ofthe face protector 110 and lens assembly in FIG. 24. In the aboveembodiments as well as in most prior art helmets or face protectors wornfor protection when welding or the like, the protective lens or cover210 can only be removed and replaced by disassembling the unit frominside the helmet. In the embodiment of FIGS. 23 to 25, an outerprotective lens or cover 610 is provided which is secured to retainermembers 615 on the outer surface of ADF retainer lens, as described inmore detail below. Thus, the outer protective lens 610 can be replacedfrom the outside, requiring no disassembly of the remainder of the lensassembly. Other parts of the lens-in-lens assembly of this embodimentare similar or identical to those in the above embodiments, and likereference numbers are used for like parts as appropriate.

As illustrated in FIGS. 23 to 25, ADF holder lens 605 has four “scrapbook”-like frame corners 615 on its outer face arranged around the lensopening or window 320. Scrap book frame corners 615 may be moldedintegrally on the front face of ADF holder lens 605, or bonded to thefront face. Outer protective lens or cover 610 is a simple rectangularlens cover of larger dimensions than opening 320 and is of transparentor at least partially transparent material with some flexibility toallow for engagement of corners 616 with the frame corners or retainermembers 615. The dimensions of the outer protective lens or cover 610substantially match the rectangular dimensions defined by frame corners615. The scrap book frame corners 615 are designed for releasableengagement with corresponding corners 616 of outer protective lens orcover 610. This allows the user to remove the lens 610 from the outsidewhen it becomes too worn or scratched for good visibility, and replaceit with a new lens cover engaged in the frame corners 615 as illustratedin FIGS. 23 and 25. Lens or cover 610 provides a second outer protectivelens which extends over and protects the underlying front cover or firstprotective lens 210 which snaps into the opening 320 of the ADF holderlens 605 via fasteners 305. In an alternative embodiment, front cover210 may be omitted altogether and replaced by outer protective lens orcover 610. In another alternative embodiment, the window opening andfront cover 210 may be replaced by a transparent window portion formedintegrally with the ADF holder lens, with the replaceable outerprotective lens protecting the window portion from damage. Other partsof the assembly of FIGS. 23 to 25 are identical to the previousembodiments, and like reference numbers are used for like parts asappropriate.

Although the scrap book frame holding the outer protective lens in FIGS.23 to 25 is designed for use with the face protector and lens assemblyembodiments described above in connection with FIGS. 1 to 22, similarscrap book frame corners may be provided around the opening in aretainer lens forming part of any prior art welding helmet or faceprotector, and a similar flat or arcuate protective lens or cover may besnapped into the scrapbook frame corners from the outside, requiring nodisassembly from the inside of the helmet or face protector in order toreplace a worn front protective lens or cover. Although the opening 620,the frame defined by frame corners 615, and the outer protective lens orcover 610 in the illustrated embodiment are all rectangular, these partsmay be of different shapes in alternative embodiments, with suitableexternal retainer members on the outer face of the retainer lensarranged around the opening for snap engagement with edge portions ofthe outer protective lens cover.

Most if not all current welding helmets or face protectors areengineered to have the protective lens cover replaced by disassemblingthe unit from the inside, as is the case with the face protectorembodiments described above in connection with FIGS. 1 to 22. Outerprotective lens covers typically become damaged with resultant reducedvisibility relatively quickly, and welders often need to replace suchcovers five or more times per day. Disassembly of such lens covers fromthe inside takes time and energy, is not user friendly, and welders haveto stop welding and take a significant amount of time to replace theprotective lens cover, reducing productivity. The embodiment of FIGS. 23to 25 overcomes this problem by allowing quick and easy replacement of aworn or damaged outer protective lens or cover, simply by snapping thecover out of the snap-book like frame corners and replacing it with anew cover snapped into the frame corners from the outside, eliminatingany need for disassembly from the inside.

The above figures may depict exemplary configurations for the invention,which is done to aid in understanding the features and functionalitythat can be included in the invention. The invention is not restrictedto the illustrated architectures or configurations, but can beimplemented using a variety of alternative architectures andconfigurations. Additionally, although the invention is described abovein terms of various exemplary embodiments and implementations, it shouldbe understood that the various features and functionality described inone or more of the individual embodiments with which they are described,but instead can be applied, alone or in some combination, to one or moreof the other embodiments of the invention, whether or not suchembodiments are described and whether or not such features are presentedas being a part of a described embodiment. Thus the breadth and scope ofthe present invention, especially in any following claims, should not belimited by any of the above-described exemplary embodiments.

Terms and phrases used in this document, and variations thereof, unlessotherwise expressly stated, should be construed as open ended as opposedto limiting. As examples of the foregoing: the term “including” shouldbe read as mean “including, without limitation” or the like; the term“example” is used to provide exemplary instances of the item indiscussion, not an exhaustive or limiting list thereof; and adjectivessuch as “conventional,” “traditional,” “standard,” “known” and terms ofsimilar meaning should not be construed as limiting the item describedto a given time period or to an item available as of a given time, butinstead should be read to encompass conventional, traditional, normal,or standard technologies that may be available or known now or at anytime in the future. Likewise, a group of items linked with theconjunction “and” should not be read as requiring that each and everyone of those items be present in the grouping, but rather should be readas “and/or” unless expressly stated otherwise. Similarly, a group ofitems linked with the conjunction “or” should not be read as requiringmutual exclusivity among that group, but rather should also be read as“and/or” unless expressly stated otherwise. Furthermore, although item,elements or components of the disclosure may be described or claimed inthe singular, the plural is contemplated to be within the scope thereofunless limitation to the singular is explicitly stated. The presence ofbroadening words and phrases such as “one or more,” “at least,” “but notlimited to” or other like phrases in some instances shall not be read tomean that the narrower case is intended or required in instances wheresuch broadening phrases may be absent.

The invention claimed is:
 1. A face protector, comprising: a face platehaving portions configured to protect the forehead, cheeks, jaw, chin,mouth, ears, and nose of a wearer, the face plate having a front openingconfigured for positioning over the eyes of a wearer and extendingrearwardly over opposite sides of the face towards the ears of a wearer;a retainer lens secured in the front opening of the face plate, theretainer lens having a front face and a rear face, a retainer lensopening configured for alignment with the eyes of a wearer of the faceprotector, and a plurality of retainer members on the front face of theretainer lens positioned around and spaced outwardly from the retainerlens opening to define a frame of larger dimensions than the opening;and an outer protective lens of shape and dimensions substantiallymatching the frame defined by the retainer members and larger than thedimensions of the retainer lens opening; the outer protective lenshaving edge portions releasably engaged with the spaced retainer membersto secure the outer protective lens over the retainer lens opening. 2.The face protector of claim 1, wherein the retainer lens opening is ofsubstantially rectangular shape and the retainer members comprise cornermembers spaced outwardly from respective corners of the retainer lensopening to define a rectangular frame of larger dimensions than theretainer lens opening, and the outer protective lens is of generallyrectangular shape and dimensions substantially matching the rectangularframe, the edge portions of the outer protective lens comprising cornersreleasably engaged with the corner members of the retainer lens.
 3. Theface protector of claim 1, wherein the retainer lens comprises anautomatic darkening filter (ADF) lens.
 4. The face protector of claim 1,further comprising a second lens of smaller dimensions than the retainerlens located behind the retainer lens and outer protective lens toprovide a lens-in-a-lens configuration, a back cover behind the secondlens, and a retainer assembly configured to releasably secure the secondlens and back cover to the retainer lens to form a lens-in-lens assemblysecured in the front opening of the face plate.
 5. The face protector ofclaim 4, wherein the retainer lens and second lens are both automaticdarkening filter (ADF) lenses, and the outer protective lens is of atleast substantially transparent material.
 6. The face protector of claim5, further comprising a set of interchangeable automatic darkeningfilter (ADF) second lenses of identical shape and different shades forselectively securing to the first lens.
 7. The face protector of claim1, further comprising a front cover member secured in the retainer lensopening behind the outer protective lens.
 8. The face protector of claim7, wherein the front cover member is of at least partially transparentmaterial.
 9. A face protector, comprising: a face plate having portionsconfigured to protect the forehead, cheeks, jaw, chin, mouth, ears, andnose of a wearer, the face plate having a front opening configured forpositioning over the eyes of a wearer and extending rearwardly overopposite sides of the face towards the ears of a wearer; a lens-in-lensassembly secured in the front opening of the face plate; thelens-in-lens assembly comprising a first, retainer lens secured in thefront opening and substantially flush with at least the forehead portionof the face plate, the first lens being of shape and dimensions whichsubstantially match the shape and dimensions of the front opening, asecond lens of smaller dimensions than the retainer lens behind thefirst lens to provide a lens-in-a-lens configuration, a back coverbehind the second lens, and a retainer assembly configured to releasablysecure the second lens and back cover to the first lens; the retainerlens having a front face, a rear face, a window portion of at leastsubstantially transparent material in front of the second lens, and aplurality of retainer members on the front face of the retainer lenspositioned around and spaced outwardly from the window portion to definea frame of larger dimensions than the window portion; and an outerprotective lens of shape and dimensions substantially matching the framedefined by the retainer members and larger than the dimensions of thewindow portion of the retainer lens; the outer protective lens havingedge portions releasably engaged with the spaced retainer members tosecure the outer protective lens over the window portion.
 10. The faceprotector of claim 9, wherein the first, retainer lens has an opening infront of the second lens which has a periphery spaced inwardly from theframe defined by the retainer members, and the window portion comprisesa separate protective cover member releasably secured in the openingbehind the outer protective lens.
 11. A lens assembly for securing in anopening in a face plate of a face protector, comprising: a retainer lensconfigured to be secured in a front opening of a face plate and having acurvature substantially matching the curvature of the face plate, theretainer lens having an outer surface, an inner surface, and a window; asecond lens of smaller dimensions than the retainer lens secured behindthe retainer lens and aligned with the window to provide alens-in-a-lens configuration; a plurality of retainer members on theouter surface of the retainer lens positioned around and spacedoutwardly from the window to define a frame of larger dimensions thanthe window; and an outer protective lens of shape and dimensionssubstantially matching the frame defined by the retainer members andlarger than the dimensions of the window; the outer protective lenshaving edge portions releasably engaged with the spaced retainer membersto secure the outer protective lens over the window.
 12. The lensassembly of claim 11, wherein the retainer lens and second lens are bothautomatic darkening filter (ADF) lenses, and the outer protective lensis of at least substantially transparent material in front of the secondlens.
 13. The lens assembly of claim 11, wherein the window is ofsubstantially rectangular shape and the retainer members comprise cornermembers spaced outwardly from respective corners of the window to definea rectangular frame of larger dimensions than the window, and the outerprotective lens is of generally rectangular shape and dimensionssubstantially matching the rectangular frame, the edge portions of theouter protective lens comprising corners releasably engaged withrespective corner members of the retainer lens.
 14. The lens assembly ofclaim 11, wherein the window comprises an opening in the retainer lensand an at least substantially transparent window member secured in theopening.
 15. A method of using a face protector with an interchangeablelens assembly, comprising: securing a lens assembly in a front openingin a face plate configured to extend over the face of a wearer toprotect the forehead, cheeks, jaw, chin, mouth, ears and nose of awearer while the lens assembly protects the eyes and areas surroundingthe eyes, the lens assembly comprising at least a first lens which fitsthe face plate front opening and has an outer surface, an at leastsubstantially transparent window that is smaller than the first lens andis positioned to extend in front of the eyes of a wearer, and retainermembers on the outer surface of the first lens spaced outwardly from thewindow and defining a frame of larger dimensions than the window;engaging spaced edge portions of an outer protective lens of at leastsubstantially transparent material with the retainer members to extendover and protect the window; applying the assembled face protector to awearer's head with the outer protective lens extending over the windowand in front of the wearer's eyes; wearing the face protector during anactivity; removing the outer protective lens from the first lens after aperiod of activity by removing the edge portions of the outer protectivelens from the retainer members; replacing the removed outer protectivelens with a new outer protective lens by engaging spaced edge portionsof the new outer protective lens with the retainer members; andrepeating the steps of removing an outer protective lens and replacingthe removed outer protective lens with a new outer protective lens atperiodic intervals as needed as a result of wear on the outer face ofthe outer protective lens.
 16. The method of claim 15, wherein thewindow comprises an opening in the first lens.
 17. The method of claim16, further comprising releasably engaging an at least partiallytransparent protective cover of smaller dimensions than the outerprotective lens into the opening in the first lens before engaging theouter protective lens with the retainer members to extend over thesmaller protective cover in the opening in the first lens.